Doing Our Best to Provide You the Best

7-08TP20080,Rev.5

Suzuki Grand Vitara &Grand Vitara XL..7

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8 REF. PART NO. NO. QTY. DESCRIPTION 1. 09812-35 1 Right Frame Mount 2. 09813-35 1 Left Frame Mount 3. 13136-35 1 Crossmember 4. 09815-35 2 Z Bracket 5. 09816-95 2 Frame Bushing 6. 05104 2 7/16”-14 UNC x 3” Hex Bolt Gr.5 7. 00078 2 7/16” Lockwasher 8. 00079 2 7/16”-14 UNC Hex Nut 9. 01254 4 1/2”-13 UNC x 1-1/2” Hex Bolt Gr.5 10. 00084 4 1/2”Lockwasher 11. 00083 4 1/2” -13 UNC Hex Nut 12. 09795 2 10mm x 1.25 Punch Lock Nut 13. 07479 2 8mm x 1.25 x 25mm Hex Bolt 14. 07286 2 8mm Lockwasher 15. 09228 2 8mm Fender Washer 16. 00523 2 3/8”-16 UNC x 1-1/4” Hex Bolt Gr.5 17. 00060 2 3/8” Lockwasher 18. 00061 2 3/8”-16 UNC Hex Nut 19. 00059 2 3/8” Flatwasher 20. 07594 6 3/8” Self-Threading Bolts 21. 09817-35 2 Crossmember Shims (not shown) 22. 12329 1 Loctite(not shown)

9518080 PARTS LIST

Please order replacement parts by PART NO. and DESCRIPTION.

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Grand Vitara: Centers-23” Pin Height-16-3/4”XL7: Centers-23” Pin Height-18-3/4”

BOLT TORQUE SPECIFICATIONS

Size Grade Torque5/16” 5 20 ft/lbs.3/8” 5 35 ft/lbs.7/16” 5 56 ft/lbs.1/2” 5 85 ft/lbs.

Size Torque8mm 22 ft/lbs.10mm 42 ft/lbs.12mm 70 ft/lbs.14mm 95 ft/lbs.

METRIC BOLTS:STANDARD BOLTS:

IMPORTANT INSTALLATION ITEMS

WARNING: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING VEHICLE CONTROL, SEPARATION OF THE TOW BAR FROM THE TOWING VEHICLE, SEPARATION OF THE TOWED VEHICLE FROM THE TOW BAR, CAUS-ING SEVERE PERSONAL INJURY, DEATH, OR PROPERTY DAMAGE.

INSTALLATION INSTRUCTIONS

NOTE: The dimensional variations between otherwise identical vehicles can be considerable. Some mi-nor modifi cations may have to be made to ensure a proper fi t.

2. Carefully pull gr i l l straight out by head-light area, and set aside.

1. Remove grill by opening hood and removing plastic push fasteners from top of grill.

DEMCO products and accessories are intended to be installed by professional installers with experience, proper equipment and the ability to do modifi cation work. Installers with these qualifi cations can be found in RV and Automotive Service Centers.

If the car to be towed has been in an accident, the chassis may be damaged in an area where the Base Plate attaches. It may no longer be suitable for tow-ing. Extreme caution and careful examination are required in such a situation. It is also likely, even from a minor accident, that the hole alignment will be more diffi cult due to hole alignment problems.

Many DEMCO Base Plates are designed to use ex-isting holes and hardware to mount the Base Plate to the towed vehicle. Even though the bolt is there, however, do not assume it is adequate for mounting the Base Plate. Manufacturers make many changes in hardware both within and between model years. Be sure the bolt is long enough to protrude past the nut a distance no less than 1/2 the diameter of the bolt, after the Base Plate is mounted. The threads should be in good condition. We require that “ R Blue” be used on all bolts. If a new bolt is required, be sure it is SAE Grade 5 or Metric 8.8.

Safety is of utmost importance at all times. There are several items that must be checked each time before using and while using a tow bar.Before allowing anyone to hook up or operate a tow bar, be sure they have read and understand the proper operating procedure.

DO NOT use worn or damaged cables and/or pins.

Be sure the SAFETY CABLES are hooked, chassis to chassis, to both the towing and towed vehicles using the crisscross method.

Check clearance between vehicles in a turning situation.

Check base plate mounting bolts for tightness and frame for metal fa-tigue.

Do not load the towed vehicle with anything as you may exceed the towing capacity of the tow bar.

Keep fi ngers away from pivot points to prevent personal injury.

Be sure the steering components of the towed vehicle are properly aligned.

NOTE: This unit can be backed up in moderate increments. Any se-vere backwards cornering could result in damage to the Tow Bar and/or towed vehicle chassis.

For automatic transmissions: Consult your vehicle owners manual for towing suitability with the drive shaft connected. Otherwise, the towed vehicle will have to be equipped with a transmission pump or drive shaft disconnect.

Check to make sure that all lights are in proper working order.

The information on towability of vehicles is reprinted with permis-sion of MotorHome© Magazine, and is believed to be reliable. However, Demco does not warrant the information to be correct. Always consult your towed vehicle owner’s manual and follow towing instructions. Each year, MotorHome© Magazine, compiles a list of vehicles that can be towed four-down behind a motorhome with no modifi cations required. This guide contains only those vehicles that have been approved by their manufacturers for towing. This list is enclosed with this manual. Caution: MotorHome© Magazine left out any vehicles that have towing speed limits slower than 55 m.p.h., or distance limits of less than 200 miles. At a minimum, these vehicles require signifi cant modifi ca-tion, such as the use of an aftermarket product, to make them towable. The availability of a Demco Tow Bar Base Plate does not imply that these vehicles can be modifi ed or that there is an aftermarket product available. Refer to your vehicle owner’s manual or consult your dealer to determine whether your vehicle can be modifi ed to make it towable. Failure to observe this precaution could result in property damage or personal injury.

CAUTION

3. Remove bumper cover by removing plastic push fasten-ers from top side, three bolts from bottom side. Remove one plastic push fastener from inner fender to bumper cover, and one bolt from inner fender to bottom of front fender, on each side.

4. Unplug side marker lights, and pull bumper cover off.

5. Remove one plastic push from inner fender to brace, which is bolted to frame, on each side. (no picture)

6. From inside of frame out put 7/16” x 3” bolt thru frame and slip bushing through outside of frame over 7/16” bolt. Do this on each side.

NOTE: For Grand Vitara XL.7, 7/16” x 3” bolt must be installed from outside of frame inwards. Do this by fi rst putting a 4” long solid wire from inside frame. Slide bushing through large hole with wire inside of it. Put frame mount up and put 7/16” bolt through mount and into bushing and bolt will push wire out of the way. Then install 7/16” lockwasher and 7/16” hex nut. Proceed to next step

7. Install right and left frame mounts. Put proper side up and push 7/16” bolt through hole and start 7/16” lockwasher, and hex nut. Start 10mm x 1.25 punch lock nut over factory stud. Push mount up so angle is fl at on front of frame, and clamp with C-clamp. Snug previously mentioned fasteners. Drill 5/16” holes through frame using mount as a template (three on each mount).

8. Remove top bumper bolt on each side and install brace with 8mm x 1.25 x 25mm bolt, 8mm lockwasher, and 8mm fender washer. Secure bottom of brace to frame mount using 3/8” x 1-1/4” bolt, 3/8” lockwasher,3/8” fl atwasher, and 3/8” hex nut. We require that “ R Blue” be used on all bolts.

9. Install self-threading bolts at this time,and tighten all previ-ously mentioned hardware to proper torque specifi cations. Remove C-clamps We require that “ R Blue” be used on all bolts.

10. Install crossmember with 1/2” x 1-1/2” bolts, 1/2” lockwash-ers, and 1/2” hex nuts. (shims are included for crossmember if needed)

11. Reinstall bumper cover, grill, and inner fenders. Note: Metal bracket that holds bottom center bolt on bumper cover may have to be bent to refasten due to interference with crossmember. Or be removed.

1. Extent and Duration of this Warranty: Your Demco product has a Lifetime Limited warranty to be free from defects in materials and workmanship under normal use and service from date

of purchase by the original (fi rst) retail owner, or until it is resold or transferred by the original owner. Any part of the Demco product found in the judgement of the

manufacturer to be defective in materials or workmanship will be repaired or replaced at the manufacturer’s option without charge for parts or labor to the original owner.

2. Manufacturer and Warrantor: Demco 4010 320th Street P.O. Box 189 Boyden, IA 51234 (712) 725-2311

3. Repair or Replacement Procedure: If your Demco product develops a defect during the war-

ranty period, promptly notify Demco customer service department. Until such notice is received, Warrantor will not be responsible for any repair or replacement.

Upon receipt of notice from you, Warrantor will have a choice of options in replacing any part it determines to be defective:

a) Warrantor may require you at your own expense to deliver or ship the part to its factory or autho-rized dealer. Any defective part will be repaired or replaced and returned to you free of charge. Any part returned to Warrantor and found not to be defective will be returned to you freight collect with an explanation.

b) Warrantor may elect to ship a new part to its dealer to be exchanged free of charge for the defective part returned by you to the dealer.

c) Warrantor may elect to ship or deliver a replacement part to your address.

4. Limitations on Warranty Coverage: Coverage under this warranty will be valid only if the cus-

tomer warranty card is returned by the original pur-chaser within 30 days of purchase.

Coverage under this warranty will be effective only when a copy of the original invoice, showing the date and loca-tion of purchase, accompanies any claim for warranty. This warranty is limited to the original owner and is NON TRANSFERABLE to a second party.

Warrantor has no liability whatsoever and this warranty is null and void if any Demco product has been misassembled or subjected to neglect, negligence, misuse, accident or operated in any way contrary to the operating and main-tenance instructions as specifi ed in the Demco Owner’s Manual for that model.

This warranty does not cover any product that has been altered or modifi ed so as to affect it’s operation, perfor-mance or durability, or that has been modifi ed to change the intended use of the product.

In addition, the warranty does not extend to repairs made necessary by normal use of parts, accessories or other equipment which in the judgment of Warrantor, are either incompatible with the Demco product, or affect its opera-tion, performance or durability.

This warranty does not cover: 1) normal wear and tear 2) road fi lm or gravel damage to paint 3) paint 4) rust damage

Warrantor has a policy of continuous product improvement. We reserve the right to change or improve the design of any Demco product, including but not limited to state of the art changes, without assuming any obligation to modify any product previously manufactured.

Warrantor assumes no responsibility to the owner for loss of use of the product, loss of time, inconvenience or other damage consequential or otherwise, including, but not limited to expense for gasoline, expense of transporting the product to the dealer and expense of returning the product, mechanic’s travel time, telephone or telegram charges, road service/towing charges, rental of another product during the time warranty repairs are being performed, travel, lodging, loss or damage to personal property or loss of revenue or earnings.

5. Limitations of Implied Warranties: All implied warranties, if any, expire and terminate upon

expiration of this warranty. Some states do not allow limitation on how long an implied warranty lasts, so this limitation may not apply to you.

6. Limitation of Consequential Damages: Warrantor’s responsibility under this warranty extends

solely to repair or replacement of your Demco product and its component parts.

Warrantor does not assume responsibility for, nor shall it be liable for, any special, incidental or consequential damages. Some states do not allow the exclusion or limitation on incidental or consequential damages, so the above exclusion or limitation may not apply to you.

7. Purchaser’s Rights: This warranty gives you specifi c legal rights, and you may

also have other rights which vary from state to state.

8. Exclusive Warranty: This is the only express warranty made by Dethmers

Manufacturing Co. on your Demco product and no agent, employee, or other person is allowed to change or add to this warranty.

DEMCO PRODUCTS ORIGINAL PURCHASERS LIMITED WARRANTY

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Dealer/Distributor Name City State

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Did you have any contact with a Demco Representative? YES NOIf YES, how satisfied were you? ❍ ❍ ❍ ❍

I would recommend this product to my family and friends. YES NO

Would you purchase again from DEMCO? YES NO

Since taking delivery, have you been contacted by the dealer? YES NO

Did you have any problems with this DEMCO product? YES NOIf YES, are you satisfied with the company’s resolution of your problem? ❍ ❍ ❍ ❍

Why did you purchase this product?

Please list the specific source of information prompting this purchase.

After purchasing this product, do you see any needed product improvement? If yes, what improvement?

What other products would you like to see DEMCO offer?

Comments

Owner’s Name: Mailing Address:

City: State: Zip Code:

Model#:

Serial #:

Purchase Date:

Owner’s Signature:

Please return to DEMCO By FAX or tri-folding this form to the backside, it is pre-addressed.

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Warranty Registration

4010 320th Street Box 189 Boyden, Iowa 51234Toll Free 800-54DEMCO (800-543-3626) FAX 800-845-6420www.demco-products.com

VerySatisfied Satisfied

VeryDissatisfiedDissatisfied

Postage

Demco4010 320th Street, Box 189 Boyden, Iowa 51234

NOTES

NOTES

NOTES

4010 320th St., P.O. BOX 189, BOYDEN, IA. 51234PH: (712) 725-2311 FAX: (712) 725-2380 or 1-800-845-6420

TOLL FREE: 1-800-54DEMCO (1-800-543-3626)www.demco-products.com